Subterranean drain device with improved filtration

ABSTRACT

A water-impervious, non-biodegradable, unitary drainage device with multi-directional rollup capability. The invention features a monolithic “sandwich” construction consisting of planar top and base sheets which are set apart by an array of supports. The supports are disposed between and integrally joined to the sheets. Selective and off-set through-cuts, in the top and bottom sheets, impart to the invention the multi-dimensional rollup capability. Rods, optionally hollow, are used as connectors to join two or more of the devices, so that their internal drain channels are in an efficient, confluent alignment. A filtering adjunct is provided that assures exclusion of particulate in soil emplacements, yet obviates the need for aggregate. The fabric used for filtration is prevented from occluding, by impaction, most drainage apertures; it being fixed to a permanent stand-off network of supportive projections from the top or bottom sheets.

CROSS-REFERENCES TO RELATED APPLICATIONS

[0001] This application is a Continuation-in-Part of U.S. patentapplication Ser. No. 10/318,644, filed on Dec. 16, 2002 by the sameinventor, entitled: Subterranean Drainage Device (in issue), which was aContinuation-in-Part of U.S. patent application Ser. No. 10/292,298,filed on Nov. 12, 2002 by the same inventor, entitled: Drainage andFooting Form Device, both for which priority under 35 USC 119(e) and 120is hereby claimed.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not Applicable

BACKGROUND OF THE INVENTION

[0003] 1. Field of the Invention

[0004] This invention relates generally to devices and constructs usedto effect subterranean drainage from building entrenchments, such asfootings, foundations and walls, where seepage and ground water are aproblem, and also under garage and basement floors where overburden ofconcrete exacerbates the drainage problem by frustrating most existingdevices or their filtering adjuncts. More specifically, this inventionembodies a filtration improvement to known planar or “sandwich” devicesthat are relatively rigid apparata, with respect to their installation,yet can be rolled up in one or two directions, as well as in twoalternate directions, while having filter fabric permanently adhered toat least one of the planar surfaces.

[0005] 2. Discussion of Relevant Art

[0006] It has long been a practice, in the construction industry, toprovide some form of drainage in subterranean structures. Ground waterseepage is an incessant problem in most non-arid regions of the worldand building footings, garage floors (multi-level) and walls facingsurface and sub-surface waters have been most susceptible to waterincursions. Many drainage devices have been provided, as well asadjuncts thereto, in order to provide adequate carry-off of theseundesired waters; some of the adjuncts provide a modicum of filtrationof the minute particulate that is so common in most soils. In manycases, the filtering mechanisms must employ more than one medium ofsifting-filtering material because of the varied aggregate and soil orsand mix in which the construction takes place. Over the years, theindustry has progressed from sealing walls and such with tar andproviding graded stone barriers between structure and earth, to the useof prefabricated drain devices combined with overlays of uniquegeo-textiles that filter out fine particulate, do not environmentallydegrade and obviate, to some degree, the need for vast amounts of stoneinterposed the structure and earth.

[0007] Although for the most part such draining, with concomitantfiltration, is performed using tiles, stone and paper/fabric overlay(such as in drywell and septic usages), conscientious builders havetransitioned to more effective and reliable forming, draining andfiltering modalities. The instant improvement, in fact, provides allthree modalities in a single device that can be used both adjacent andbeneath concrete structures.

[0008] Two patents are germane to discussion of the present invention:U.S. Pat. No. 5,466,092, issued Nov. 14, 1995, entitled: FORM-DRAINFILTER and U.S. Pat. No. 5,634,741, issued Jun. 3, 1997, entitled:FORM-DRAIN FILTER CLAMP. To my knowledge, this was the first combinationof a concrete form, that was communicative (through multiple foramens)with ground waters and was provided a filter adjunct comprised ofgeo-textile fabric. The former reference established the principle thata filter fabric might be secured to the surface of the form-drain bysome adhesion means, while the latter provided physical mechanisms(various clamps) that effected the same attachment. Further, the lattershows a dual-channeled drain. The main limitations in this art followfrom the single purpose nature of the drain device—it is a concreteform, and no more. Also, fixing the fabric to the discrete units of thedrain may present set-up cutting problems, in the field. Thus, thesedevices do not reflect the broad range of usefulness acquired by thesub-surface drainage devices, with filter, shown in the instantdisclosure and its cross-referenced applications.

[0009] Unfortunately, with the use of a smaller and multi-channel, moreflexible and sophisticated drainage device capable of far-ranging usage,comes the likelihood of filtering problems that require a more elegantstructure, especially if the filtering element is to be provided duringmanufacture. That a filter is desirable, given the nature of very smallaperture drain mechanisms, is rationalized by the observation that evenwater can be impeded, in its passage through the apertures, if thefabric is pressed into the perforations by concrete or soil overburden.

[0010] As indicative of the art that pre-existed before the abovepatent, U.S. Pat. No. 3,888,087, for FOUNDATION WALL PROTECTIVE SHEET('087), offers one of the first devices for providing dimples (posts ordetents), as a stand-off mechanism for spacing a filter fabric from thesingle plane base of the device, and a physical folding crease toaccommodate bending about a foundation. This apparatus is quiteflexible, but using only a filter fabric as a second ply, it lacks theoverburden capability for which I designed my planar devices. Further,and of significant detriment, is the requirement that the filteringmedium be applied in situ, when the devices are installed.

Incorporation by Reference

[0011] Because they show both the present state of the art in drainagedevices having an internal channeled structure, as well as disclosingfiltering adjuncts or various standoff mechanisms, U.S. Pat. Nos.5,466,092, 5,634,741 and 3,888,087, with the aforesaid priorityapplications, are hereby incorporated by reference.

Definitions

[0012] Generally throughout this disclosure, words of description andclaim shall have meanings given by standard English usage; however,certain words will be used that may have a more stylistic meaning andare defined as follows:

[0013] construct—herein, generally, an article or a building structure;

[0014] continual—having intermittent, or periodic, breaks ordiscontinuities;

[0015] continuous—having no breaks or discontinuities;

[0016] integral—necessary to complete or in itself complete;

[0017] nodule—a projection of indefinite shape that can be sinuous,elongate or be, simply, a detent or post;

[0018] off-set—a term describing the state of slices, or slice patterns,that are parallel to others of the genre, but not overlapping norsuperposed—as opposed to “alternating”, which compels an orderedoff-setting of patterns;

[0019] partitio—an projection separating two planar sheets, incipientlycontinuous but rendered continual by various slices, according to theinstant teaching;

[0020] permeable—anything, having a character that allows a substance,such as a fluid, to pass through it;

[0021] posts—as used herein, projected elements, also dimples (in priorart) or detents;

[0022] rigidity—a physical property of an object wherein the objectsubstantially resists deflection in a particular dimension (direction)or plane;

[0023] sandwich—the configuration made by placing one planar surfaceover, but set apart from, another;

[0024] slice—a through-cut in the surface(s) of the invention thatpasses through an intervening partition, but does not penetrate theopposite surface or plane;

[0025] stand—off—a spacing element or device;

[0026] tent—a sub-structure of the instant invention that consists of afixed draping of the filter fabric over or about a drain device surfaceaperture from which the fabric, as well as particulates, must beexcluded;

[0027] tubule—a support element of the filter structure that defines,generically, any and all support projections having tube-likemorphology, whether hollow; and,

[0028] unitary—having wholeness, as in a single unit or monolithcomposed of plural members.

[0029] The above listing is not exhaustive. Certain other stylizedterms, used previously or hereafter, are defined at the time of theirfirst usage or placed in quotation marks and used with conventionalwording.

BRIEF SUMMARY OF THE INVENTION

[0030] The deficiencies or limitations of the earlier art are overcomeby providing an inexpensive, easily applied innovation allowingcontinued rollup capability to a state-of the art drain device thatbears a fixed filter fabric over at least one surface.

[0031] The preferred embodiment of the invention is worked on apre-existing drainage device that consists in a generallywater-impervious, semi-rigid plastic “sandwich”, having top and bottomplanar members separated by a series of parallel partitions or a postmatrix; either forming an integral and monolithic unit with the planarmembers. Foramens are provided on the surface that is interposed thedevice and a water source, such as ground or under-the-floor seepage.Whether the partition, or post, interstitial paradigm is employed,remains a manufacturer's and consumer's choice. In either structure,channels are formed for the communication of waters through a surface ofthe sandwich and into a drainage network. The sandwich device is, initself, capable of withstanding considerable overburden withoutcollapsing. The instant invention modifies the sandwich device byplacing in it a series of linear slices (“cuts”) that imbue the sandwichwith the desired high degree of flexibility, while retaining essentiallyall of its structural strength.

[0032] To prevent soil or concrete overburden from pressing filterfabric into the apertures or foramens of the drain device, multipleshort projections known as dimple, detent, partition, post or nodulenetworks/arrays are employed as stand-off mechanisms. These stand-offsprovide supports, the tops of which are overlain by, and fixed to, thegeo-textile filter fabric.

[0033] The stated goal being achieved, there is acquired not only adevice that has unlimited in-ground use, with high overburdensustainability, but one retaining a high degree of flexibility thatallows compact rolling, for ease in handling, storage and shipment.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0034] Of the Drawings:

[0035]FIG. 1 is a prior art illustration of a subterranean drainagearticle that is improved by the instant invention;

[0036]FIG. 2 is a plan view of the FIG. 1 device conformed to theimprovements of the invention;

[0037]FIG. 3 is an elevation of the invention, taken at 3-3 of FIG. 2;

[0038]FIG. 4 is a plan view of the FIG. 2 device conformed to theimprovements of the alternate embodiment of the invention;

[0039]FIG. 5 is an elevation of the alternate embodiment of theinvention, taken at 5-5 of FIG. 4;

[0040]FIG. 6 is an elevation of the alternate embodiment of theinvention, taken at 6-6 of FIG. 4;

[0041]FIG. 7 is an isometric illustration of the invention featuringpost-type projections;

[0042]FIG. 8 is a plan view of the invention featuring cross-patternslices of the alternate embodiment;

[0043]FIG. 9 is a drawing of an article of the invention, as derivedfrom FIG. 1;

[0044]FIG. 10 is a copy of FIG. 5 showing the filter adjunct incross-section;

[0045]FIG. 11 is a copy of FIG. 6 showing the filter adjunct incross-section; and

[0046]FIG. 12 is a detail, taken at 12 of FIG. 11.

DETAILED DESCRIPTION OF THE INVENTION

[0047] The drainage device of the prior art, shown in FIG. 1, isemployed in construction situations where there is required an unusualstrength to sustain heavy earth, gravel or concrete overburdens, such asthose encountered in basements, parking garages and earthworks. It ispackaged as stacked elements and, because of its monolithic structure,resists the tendency to roll or curl that attends a segmented ordiscontinuous structure. For the most part, there is shown here a firstexample or exhibit EX1 of the device, and a second, EX2, joined by anadjunct, a hollow coupling rod or spline R, devised by the instantinventor to aid in the alignment of the apparatus. In the prior art, thedevice is either affixed to a wall or lain on a prepared earthwork.Perforations or holes H are provided so that seepage will readily enterthe otherwise liquid-impermeable top plane. For the sake of clarity,such hole H illustrations will be generally omitted from subsequentdrawings, with but a nominal few being shown in FIGS. 4, 7 and 8. Finalto installation, a filter fabric F is overlain the device(s), to excludesoil particulate or liquid suspensions that could foul the drainchannels D; filtration is improved, hereinafter.

[0048] Referring to FIG. 2, there is shown a partial cut-away plan viewof the preferred embodiment of the invention 10. The monolithic,non-biodegradable and, preferably, polymeric plastic structure consistsintegrally in a top plane 12, a bottom plane 14 and an interstitialparallel partition 16 structure. That the separating partitions areperpendicular to the separated planes 12,14, as shown in thepost-separated model of FIGS. 7 and 8, is not a hard and fast rule ofthe instant inventor. Because the article of this invention is mosteasily acquired by the process of extrusion, almost any strength-lendinginterstitial structure may be realized; for example, X-shaped supports(not shown) would do just as well in providing weight-bearing strengthand shape retention. The only attribute required, besides the foregoing,is that water passages or drain channels D be provided.

[0049] Continuing in FIG. 2, slices 18 are shown in the top plane; suchtop plane slices are continued through any intervening supports and aretermed, simply, support slices 20. It must be noted here that thesupport slices 20 are confined only to the support mechanisms 16 and donot enter the bottom plane 14. Referring to the cut-away portion of FIG.2, there can be seen a single instance of a bottom plane slice 19, inoff-set relationship with any top plane slice 18. Like the slicingtechnique used in the top plane, bottom plane 14 slices 19, cut throughany intervening support 16, but not the top plane 12. FIG. 3, taken at3-3 of FIG. 2, exemplifies this feature of the invention. Referringspecifically to FIG. 3, this elevation view, looking into the partitionstructure, shows the top plane 12 slices 18 penetrating the interveningpartition 16 as partition slices 20; but, the slices do not penetratethe opposite plane 14. The off-set character of the slices in a planesurface cutting through only intervening supports, but not the oppositeplane, forms the nexus of the invention. It is this unique techniquethat allows the invention to be rolled into two dimensions, above orbelow the plane shown in FIGS. 1, 3, and 5-7. It is stressed that theinstant inventor teaches an off-set slicing technique, rather than an“alternating” one. In this invention, the manufacturer has, for anyreason, the option of employing any slice pattern in an ordered ornon-ordered manner, depending on the desired degree of flexibility (andthus, roll ability).

[0050] In a cut-away plan view, FIG. 4 depicts an alternate embodimentof the invention 10 having another off-set slice pattern, similar tothat of FIGS. 2 and 3, but in an orthogonal or cross-hatch array. Thisembodiment features the second array composed of parallel top slices 22and bottom slices 23; here, the slices 22, 23 are off-set from eachother and situated, at closest proximity, between adjacent partitions.Holes H are show in nominal quantity, in communication with the channelsD. It should be understood that such perforations may take on a host ofshapes or sizes, often chosen by a consumer, depending on whether itintends to use fabric or aggregate interposed the device and a seepagesource.

[0051]FIGS. 5 and 6, taken respectively at 5-5 and 6-6 of FIG. 4, areanalogous to FIG. 3, showing, in two views, that the second slicepattern differs little from the first, but now lends furtherbi-directional roll ability in the second, orthogonal dimension of this“sandwich” plane. Again, the hole(s) H shown is(are) nominal, andrepresent plural such apertures in the design.

[0052] The isometric illustration of FIG. 7, along with its correlativeplan view, FIG. 8, show, essentially, the invention 10 previouslydescribed, but in an alternate embodiment 11. Here, the invention takeson the basic aspects of the instant inventor's earlier work: a bottomsheet 14 of non-biodegradable, plastic type of material (ABS, PVC, CPVC,polypropylene or similar); truncated post-type projections 17, from andintegrally joined to the base sheet; and a top, planar structure 12secured to the tops of the posts 17. The top structure effected here(and in his earlier work) is a plurality of strips, but it is mostaccurately defined as a continuous planar sheet that is rendereddiscontinuous by one or more slices 18, as shown. All other previouslydisclosed incidents of the invention are present, including: holes H inone surface (of the plane/sheet); off-set top and bottom slices 18, 19,running in one direction; a second set of similarly off-set top andbottom slices 22, 23, running essentially 90° to slices 18, 19;drains/channels D; solid or hollow coupling rod R; and, as seen in FIG.7, filter fabric F.

[0053] Earlier, it was discussed that the invention readily lent itselfto an extrusion construction process. However, this is not a limitingfactor in its physical realization. As shown in FIGS. 7 and 8, bottomplane 14 projects cylindrical posts 17, which portray, in the abstract,any variety of fiusto-geometrical constructs, such as rectilinear,trapezoidal or cylindrical detents, dimples or projections. [NOTE: Asshall be seen hereinafter, networks of similar projections are useful onthe surface of one or both of the planar surfaces for attaching theaforementioned filter fabric so as to maintain it in set apartrelationship with the surface, particularly away from, but yetproximate, any slice, hole or similar aperture in that surface, andthus, obtain improved filter characteristics.] Such constructs areformed by extrusion, molding, machining and/or rolling mill techniques.Subsequently, the top plane(s) 12 is(are) affixed to the lowerplane-support ensemble and final machining takes place to achieve thecharacter of this instant invention. Since the field is well informed ofthe manufacturing techniques employed to make this invention, furthercomments of this nature are now deferred. After the top plane 12 isprovided, machining is performed, as necessary, to acquire the cuts orslices 18, 19 and holes H.

[0054] Addressing now the improved filtration aspects (ibid., aboveNOTE), FIGS. 9 through 12 define multiple projection features that areprovided as filter fabric supports, but which are permanently fixed tothe fabric during the manufacturing process. Because the slices 18, 19,22, 23 and holes H are vulnerable to fabric impaction, when theinvention is employed as a concrete form, or must sustain a heavyoverburden, a stand-off mechanism for the fabric and secured fabricproves invaluable. Adhering the fabric cannot be reasonably done on thejob because such an activity is time consuming and requires coatingapplication skills not readily available during the footing installationand subterranean phases of construction.

[0055] Referring to FIG. 9, there is shown a subterranean drainage/formdevice EX1 of the familiar sandwich construction consisting, minimallyof a top plane 12 over a bottom plane 14, both planes spaced apart butintegrally joined by a plurality of partitions 16. Upgrading this deviceto the drain of the instant invention is done by the previouslymentioned machining/milling techniques; here, such provide slices 18 andholes H. The crux of this improvement, relating to filtration, lies inthe technique of providing , on one or two of the planar surfaces, anarray of stand-offs or projections that serve as props for is the filterfabric F tenting (not shown). The clear distinction of fabric usage,herein, is the adhesion of the fabric to tops of all, or a preponderanceof all, the projections. Further, the projections are of varied forms,construction and adaptation: the forms including tubules 100,arced/sinuous tubules 102, dimples/detents 104, split platforms (button)106, and ribs/vanes 108; the construction being integral (with initialextrusion or molding), milling, and high viscosity lay down; and,adaptation of the projections to the fabric by pre-formation (asintegral construction) and adhesion or concurrent projection formation(say, by extrusion of adhesive) and overlay of fabric with adhesion,just prior to completion of adhesive curing. Most of these methods arein current use in a number of industries such as that which producescellular window treatments, vehicle body repair, and even dentistry. Itis not the purpose of this disclosure to discuss the many manufacturingtechniques available for realizing the invention; hereafter only theresultant articles are related.

[0056]FIGS. 10 and 11 show the filtration improvements adapted to thearticles of FIGS. 5 and 6, respectfully. In these figures, it should beunderstood that the type of projections used, as well as types andquantities, remain the manufacturer's prerogative. The straightprojections (or nodules), e.g., 100, 108, that parallel the drainchambers, are readily extruded with the sandwich production (FIG. 9,EX1). These, as well as the remaining types, 102-106, are applied as orwith adhesive or by milling/stamping. The advantage of using an adhesivefor the creation of the projections is that the fabric can be appliedduring the curing process. It would seem that the most economical formsconsist in detents/dimples 100, tubules 104 and ribs/vanes 108 (seephantom plurality in FIG. 11), in order of expense. The platform/button106 would be practical if the planes 12, 14 were molded separately. Thefilter fabric is shown as a wrap in FIG. 10 and “laminated” in FIG. 11,yet again a manufacturer's choice for acquiring the extensive tentfeature of the invention.

[0057] Finally, the detail 12, of FIG. 11, is presented in FIG. 12 toillustrate that during the adhesive lay down phase, it may be useful,and therefore preferable, to employ a lamination or contact of thefabric F directly to certain non-aperture portions of the drain device(see 110 in leftmost portion). Transverse strips along the full lengthand width of the device would facilitate cutting the sandwich duringinstallation and could also be used to provide slack in the fabriccovering, to aid in rolling the finished drain.

What is claimed is:
 1. A filtering adjunct to a sandwich-type,subterranean drainage device comprising: a network of stand-off elementsthat are fixedly disposed on, and project from, a planar surface of thedevice; and, a fluid-permeable filter fabric overlain and adhered totops of the elements, effecting a filter cover over, and set apart from,said surface.
 2. The adjunct of claim 1, wherein said elements aresupportive projections selected from the class of formations consistingof tubules, detents, posts, ribs, elongate fins and sinuous/arcednodules, which are formable by extruding, molding and lay-downtechniques.
 3. The adjunct of claim 2, wherein sufficient elements aredisposed proximate a preponderance of apertures in the surface to effecta fixed fabric tent structure.
 4. The adjunct of claim 3, wherein thefabric is adhered to the surface at selected non-aperture portions tofacilitate cutting of the device.
 5. A particulate filtration system foruse with a sandwich-type, surface-aperture and interiorly channeledsubterranean drainage device comprising a geo-textile filter fabricoverlying and joined to tops of a plurality of discrete, fixedprojections that emanate from at least one planar surface of the device,and including placement of the projections effectively about anyaperture in said surface to effect a stand-off tenting of the fabricover said aperture.
 6. The system of claim 5 further comprisingprojections of at least one morphology selected from the class offormations consisting of tubules, detents, posts, ribs, elongate finsand sinuous/arced nodules, which are formable by extruding, molding andlay-down techniques.
 7. The system of claim 6 wherein the fabric isadhered to the surface at selected non-aperture portions to facilitatecutting of the device.
 8. In a sandwich-type, channeled drainage devicethat features at least one planar, multi-aperture surface, over which ageo-textile filter fabric is superposed, an improvement characterized bya multiplicity of stand-off elements disposed on and extending in asubstantially orthogonal projection from said surface into fixedcontacts with said geo-textile filter fabric, thereby effecting a fabrictenting that is discretely held and spaced away from at least apreponderance of apertures in said multi-aperture surface.
 9. Theimprovement of claim 8 wherein the fabric is adhered to the surface atselected non-aperture portions to facilitate cutting of the device. 10.The improvement of claim 8 wherein said elements are projections ofvarying shapes and sizes so as to present a rigid, fabric-securingsupport structure proximate said at least a preponderance of apertures.11. The improvement of claim 10 wherein said varying shapes of saidelements are selected from the class of forms consisting of tubules,strings, arcs, ribs and flats.
 12. The improvement of claim 10 whereinsaid varying shapes of said elements are molded into the device.
 13. Theimprovement of claim 10 wherein said varying shapes of said elements areextruded with and as an integral part of the device.
 14. The improvementof claim 10 wherein said varying shapes of said elements are adhesive incharacter and are applied to the device after its construction.